So after putting it off for way too long, I decided to finally build my new rear bumper for my 86 4runner. My stock bumper (frame mounted with a tow hitch) was not only rusted to heck, but sharp, weak, and obviously ugly.

Requirements for new bumper:

-Hi-Lift Jackable
-Tow hitch/recover points
-Aesthetically
-Able to be expanded on (carrier in the future?)
-Frame mounted
-Higher depature angle
-Economical!!

Heres how the old bumper looked:



The old brackets... (one was completely shot) I had to torch them out with the oxy-act because the bolts were so far gone.


For the new brackets, i wanted to keep the design of the old one, especially for the drop down to clear the tailgate and allow me to fully use it. I used some 2ish foot long pieces of 3/16" steel angle iron, cut out angles with a wheel and welded them up.





I had to cut the tops of the part that slides in the frame so they could come out once welded to the bumper. Each bracket is bolted in the two stock holes in the rear of the frame. I used 1/2" Grade 10.9 bolts that were about 1.5 or 2 inches long.



Heres how they look from the tailgate down.





I couldnt decided what i wanted for a main beam for the rear, but i couldnt complain when i got a ton of 3" DOM tube for 10$ at the scrap yard, so it was an easy decision.



Its kinda skimpy by the looks, but definately strong enough for me. I notched the brackets in the back and clamped the tube up. I kept it out from the back a bit so it could double as a step for roof access or anything.







And a shot from underneath:



Then i tacked it, hit it with a wire wheel and gave it a quick coat of primer. Im not done, but it needs to be roadworthy so its done for now! Its much smaller than some of the other custom ones ive seen on here, but definately does the job and serves its purpose. I plan on doing another tube inside and doing a tow hitch welded into both. I also have to truss the tube to the brackets, cap the ends and a few more touch up things but overall Im very pleased. Everything took about 4 hours from start to finish. It cost about 20$ between the steel, rods and misc other stuff. Wicked Cheap! Hope you guys like it.




I welded everything with 1/16th E6011/6013 rod on my trusty old 110V Craftsman Stick welder.

 

I like. Keep it simple.

 

Some pictures of planned improvements for the bumper when i get a chance to play around with the welder later on this month. I want to incorporate a tow hitch into it at some point as well. I've been playing around with some force diagrams for placement, but i prefer trial and error over Solidworks anyday! Any and all input is appreciated

...This is what happens when you get bordered in statics and thermodynamics class!


here's a shot from above/side of bracing and frame improvements, all will be most likely 1/4" or 3/16" stock. the tow hitch portion will either be a recycled tow hitch or just a welder reciever to a cross beam which would then be bolted into my brackets.



mock up of side protection extensions. i plan to get rid of the plastic guards on the rear quarter panels.



tire carrier possibly? maybe im dreaming a little too much! but i really wanna do one soon.



more of the tire carrier and some ideas for a modified latch just for kicks.

 

looks awesome ahaha!

 

good progress.

 

hey no-one said it had to be expensive to do the job right...I like your ideas for reinforcing/adding a hitch, and a tire carrier...looking good.

 

Well it took a little while to get done, but i finally pulled my bumper off while i was on break from school and added the recovery points i had hoped to. (You know, for pulling out those stuck poor little things called jeeps) I was originally going to just do a trailer hitch in the middle, but I had some stock 3/8" plate lying around so i kept with the simple and cheap theme and didnt buy anything new. Unfortunately I dont have any pictures specifically of the assembly or welding, I did it later in the day and was in the 'git er done' midset.

Basically, I cut slots in the tube, right next to the frame mounts, and slid a piece of 2"x3/8" flat stock next to the bracket and lap welded them together. Then rounded off the protruding end of the bar and bored a 3/4" hole for clevis mounts.



Here's a close up of the lap welds. They go all the way around and continue onto the bumper tube. Welds were done with a 220V Century 180 Mig with .023 wire. My 110V isnt quite capable of 3/8"...



A bit farther back, from the other side. I decided to leave the bumper out a bit from the tailgate instead of tuck it up tight. Part because it offers a bit more anti-vehicle road protection, and also because its a nice step, seat, rest in general.



I've already winched/pulled off of this and it has held its own just fine. The 3/8" recovery mounts really beef it up alot without the added weight of having everything be ridiculously overkill.

Sorry for the sub-par pictures, my camera was misbehaving a bit. Hope ya guys like it!

In all her glory under a lampost in the school parking lot.

 

Looks good!! I want to make something similar for my 2nd gen 4runner. I built some side panels out of scrap plate steal which only cost $15 . I think im going to have to steal your idea for the hitch and tire carrier part tho